Clog-resistant inlet for a conduit of a water treatment system

ABSTRACT

A nozzle is provided for a header conduit. The nozzle includes an inlet that is resistant to clogs caused by flat materials covering the inlet. The inlet generally includes multiple pathways to an elongated passageway through which waste liquid and sludge (“waste”) are guided and enter the header conduit. In one embodiment, the elongated passageway is oriented to guide the waste along a path that is tangential to at least the inner surface of the header conduit which such incoming waste first contacts. When the conduit has an inner surface of circular cross-section, the passageway may optionally be elongated enough that the incoming waste enters the header conduit along a path tangential to the circular surface. To better assure axial flow of the waste in the conduit to an outlet, in one embodiment the passageway provides both the tangential flow and is at an acute angle to the longitudinal axis of the conduit. The incoming waste is thereby provided with an axial component. In this manner, the passageway assures that the energy and momentum of the incoming waste is helical in direction. The waste previously admitted into the header conduit is urged by the newly entering waste to continue to flow helically in the conduit. The passageways are provided at spaced intervals along the length of the conduit to collect sludge from a wide area of the bottom of the basin. Because of the tangential orientation of each of the passageways and the resulting initial tangential flow of the incoming waste, the waste incoming from each of those multiple passageways reinforces the existing helical flow of waste in the conduit.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation application and claims the benefitand priority of U.S. patent application Ser. No. 16/144,645 filed Sep.27, 2018 and entitled “Clog-Resistant Inlet for a Conduit of a WaterTreatment System,” now U.S. Pat. No. 10,675,562, which is incorporatedherein in its entirety by reference.

FIELD

This invention relates to removal of solids from liquid, and moreparticularly, to a clog-resistant inlet for a header conduit forremoving the solids from the liquid contained in a basin of a water orwaste water treatment facility.

BACKGROUND

Basins are used to collect certain materials and particles from liquid,to clarify the liquid. These materials are initially suspended in theliquid. They are subject to the force of gravity when the flow of theliquid is substantially reduced, as in a very low flow, or quiescent,zone (or flow channel) in the basin, and settle to the bottom of thebasin. The settled materials and particles are removed from the bottomof the basin by being drawn into a header conduit that may traverse thebottom of the basin. Since these materials are generally solid and aresaid to “settle” out of the liquid, they are referred to as “settleablesolids”, or “settleable particulates”. Upon settling onto the bottomthey are generally referred to as “sludge”. Such settleable solids mayinclude naturally occurring materials (e.g., clay, silts, sand anddirt), chemical precipitants, biological solids, and stringy materialssuch as fibers. The words “material” or “solids” or “sludge” as usedherein to describe the present invention refers to all such settleablesolids and settleable particulates.

Basins are used, for example, in water and waste water treatment plants.In water treatment, the water drawn from a water supply has variousnon-settleable colloidal solids therein. When mixed with chemicals, thecolloidal solids and chemicals agglomerate to form solids. In wastewater treatment, the solids include organic solids, among other wastes.Water and waste water are treated in basins to remove such solids,thereby making the water clear and suitable for use, reuse, or forfurther treatment, such as tertiary treatment. The word “liquid” as usedherein to describe the present invention refers to water and wastewater.

An object of water and waste water basins is to create the quiescentzones having low flow rates to promote maximum settlement of the solidsto the bottom of the basins. Typically, basins include a large area forcontaining the liquid and the solids where the settlement of the solidsoccurs. Such settlement has been promoted in small area basins by use ofplate or tube settlers. Regardless of how the solids are caused tosettle from the liquid in the basin, there is a need to remove thesettled settleable solids and settleable particulates (i.e., the sludge)from the basin to provide room for additional solids and particulateswhich settle.

Various devices have been used in basins to remove the sludge from thebasin. Among these are the well-known reciprocating sludge collectordescribed in U.S. Pat. No. 4,401,576 which is incorporated herein byreference in its entirety. Other sludge collectors have been mounted topivot on an axis at the center of a circular basin. Whether thecollector reciprocates or rotates on an axis in the basin, a headerconduit of the collector is generally caused to move relative to thebottom of the basin into the sludge which collects on the bottom.Negative pressure is applied to one end, or to a central point, of theheader conduit in an attempt to cause the liquid and the sludge to flowfrom the bottom of the basin and enter apertures formed through the wallof the header conduit. The apertures are generally formed by removing aportion of the wall of the header conduit, which is typically acylindrical pipe or a triangular cross-section conduit made from 14gauge (75 mil) material. The liquid and the sludge enter the pipe in thedirection of a diameter of the pipe, and for sludge removal musteventually turn so as to flow axially in the header conduit toward thedownstream point at which the negative pressure is applied to the pipe.Despite some developments in removal of sludge from basins, problemshave been experienced in attempting to efficiently remove the sludgefrom the basin using such header conduits.

SUMMARY

Applicants' studies of these problems indicates that the flow of sludgeinto such header conduits has often become blocked upstream of theheader conduit as the header conduits are moved into the sludge. Themovement tends to compact the sludge ahead of the header conduit, makingit more difficult for the negative pressure applied to the headerconduit to cause the sludge to move toward and into the apertures. Thisdifficulty is compounded by the requirement that in prior headerconduits having such apertures, the incoming liquid and sludge mustabruptly turn from the diametrical path and change direction under theaction of the lower pressure liquid and the sludge previously admittedinto the header conduit. This change in direction dissipates some of thekinetic energy of the incoming liquid and sludge. As a result, backpressure tends to build up at the entrance to the aperture, the flow ofsludge into the header conduit slows, and the sludge tends to pile up infront of the header conduit. In header conduits having the basin, thesludge has been observed flowing over the header conduit to the rear ofthe header conduit, where it is less compacted and tends to flow downand into the aperture through what is a path of least resistance to theapertures.

This approach to sludge collection is inherently subject toinefficiencies because, for example, the build up of sludge in front ofthe header conduit increases the energy needed to move the headerconduit through the sludge, rendering the sludge collection operationmore costly.

Applicants' have further determined that the apertures of such headerconduits tend to become clogged with sludge. For example, in thetreatment of waste liquids from so-called stone-washing operationsperformed on denim clothing, fibers from the denim material aredislodged from the clothing and have to be removed. These fibers arelong, such as two inches. As the header conduit is moved into thesludge, including into the fibers, and with the negative pressureapplied to the header conduit, the fibers flow toward the apertures andfor sludge removal must turn just downward of the aperture at a rightangle so as to flow into the axial length of the conduit. Due to thelength of the fibers, and other factors, a fiber often becomes caught onthe edge of the apertures, and causes other solids to collect there,thus clogging the aperture.

Inlets to the apertures of the header conduit may also be blocked byflat pieces of material, such as leaves, paper, or plastic, in thebasin. As the sludge, including the flat material, flows toward theheader conduit, the flat material may become lodged over an orifice ofthe aperture obstructing the flow of sludge into the header conduit.

Applicants have also studied the flow of such liquids and sludge in suchheader conduits. It appears to Applicants that the head loss in suchheader conduits varies from one axial location to another axial locationin the header conduit as the flow of sludge and liquid moves downstreamto the outlet to which the negative pressure is applied to the headerconduit. This appears to cause fluctuations, or pulses, in the flow.These head loss variations appear to result from the liquid and thesludge entering the header conduit along such diametrical path, hittingagainst the wall of the header conduit opposite to the aperture, andforming a mushroom-shaped volume of higher pressure (as the velocity ofthe incoming liquid and sludge is converted to pressure), before tendingto turn and flow toward such inlet of the header conduit. The presenceof this higher pressure volume opposite to each aperture tends torestrict the rate of flow past each of the apertures, rendering thecollection operation less efficient. Also, the varied pressure allowsthe sludge at the lower pressure locations to settle out of the flowingliquid and drop onto the bottom of the header conduit where it tends tocome to a stop. Once stopped, it takes more energy to overcome theinertia of the stopped sludge, and the stopped sludge tends toaccumulate more sludge, further decreasing the efficiency of thecollection operation.

The present invention seeks to overcome these and other limitations ofthe prior header conduits by addressing each of the four above-discusseddisadvantages of the prior header conduits. In particular, nozzles ofsome embodiments of the present invention are configured to directliquids and the sludge to enter the header conduit along a well-definedpath that is tangential to at least the inner surface of the headerconduit which is first contacted by such incoming liquid and sludge uponentering the header conduit. In one embodiment, in which the headerconduit has an inner surface of circular cross-section, the nozzle maydirect such incoming liquid and sludge to enter the header conduit alongsuch a path that is tangential to the circular surface. Applicant'sstudies indicate that the momentum of those incoming liquid and sludgein the tangential path causes them to immediately tend to assume acircular path within the header conduit, such that much of the velocityof the incoming liquid and sludge is retained. Rather than flowing intothe header conduit and having to sharply turn, as with the apertureswhich have tended to block the easy flow into the header conduit andcause the sludge to pile up in front of the header conduit, thecontinued velocity of the incoming liquid and sludge encourages thesludge in front of the header conduit to enter the header conduit.

At the same time as such circular flow continues, the axial flow of theliquid and sludge previously admitted into the header conduit, or anaxial force at the closed end of the header conduit, tends to cause theliquid and the sludge entering the conduit to have an axial component.As a result, those liquids and sludge newly admitted tangentially intothe header conduit flow axially and circularly within the header conduitto the outlet, and retain much of the velocity they had when theyentered the header conduit. Further, such tangential flow into theheader conduit avoids catching the long fibers on an edge of the headerconduit, avoiding a problem of the prior art apertures.

Moreover, as is known in the art, multiple places are provided for theliquid and the sludge to enter the header conduit. This is intended toassure removal of the sludge from all areas of the bottom of the basin.In one embodiment, the header conduit includes nozzles configured suchthat the liquid and the sludge entering the header conduit from each ofthose multiple places should reinforce, rather than hinder, the existingflow of the liquid and the sludge in the header conduit. Applicants'provision of such tangential flow into the header conduit tends toreinforce the circular flow in a circular cross-section header conduit,or in another conduit having generally circular flow. This is done byhaving the newly incoming tangential flow join in the circular directionwith the circular and axial flow of the liquid and sludge previouslyadmitted into the header conduit. This joining and resultant reinforcedflow is contrary to the head loss periodically caused to occur in theprior art header conduits due to the mushrooming effect of thediametrically flowing liquid and sludge entering the header conduitthrough the spaced apertures. With the joined and resultant flowcontinuing generally with the same (or somewhat increased) velocity asthe flow passes each point of tangential entry of the liquid and sludgeinto the header conduit, there are no places along the flow path to theoutlet at which the sludge tends to settle out of the liquid.

With these and other features in mind, the header conduit of oneembodiment of the present invention provides a nozzle (rather than anaperture) through which the liquid and the sludge are guided and enterthe header conduit along a path that is tangential to at least the innersurface of the header conduit which such incoming liquid and sludgefirst contact upon entering the header conduit. When the header conduithas an inner surface of circular cross-section, the nozzle is elongatedenough that the incoming liquid and sludge enter the header conduitalong such path that is tangential to the circular surface. The nozzleorganizes the incoming flow into the tangential path to assure that themomentum of those incoming liquid and sludge causes them to tend toassume a circular path within the header conduit. As a result, much ofthe velocity of the incoming liquid and sludge is retained. Thecontinued velocity of the incoming liquid and sludge in the circularpath avoids undue back pressure at the inlet of the nozzle andencourages the sludge in front of the header conduit to enter the headerconduit.

At the same time as the nozzle directs the liquid and sludge into theheader conduit in the tangential path and the circular flow thereofcontinues, the circular and axial flow (i.e., the helical flow) of theliquid and sludge which were previously directed into the header conduittends to cause the liquid and the sludge that have newly entered theheader conduit to develop an axial component so that the newly enteredliquid and sludge join the helical flow of the previously admittedliquid and sludge. As a result, those liquids and sludge newly admittedinto the header conduit flow axially and circularly (in a helical path)within the header conduit to the outlet, and retain much of the velocitythey had when they entered the header conduit. Such tangential flow intothe header conduit, followed by such helical flow, avoids catching thelong fibers on an edge of the nozzle, avoiding a problem of the priorart apertures.

The nozzles also include inlets that are configured to be resistant toclogging and blocking by flat materials. Blocking of the nozzles isprevented by the geometry of the inlets. An inlet may include aplurality pathways leading to a passageway through the nozzle. If oneinlet is obstructed, the flow of the liquid and sludge into thepassageway and through the nozzle to the header conduit will continuethrough another one of the inlets. The inlets may also have a geometrythat prevents complete blockages by flat material such that if a portionof an inlet is blocked, liquid and sludge can flow past the flatmaterial and into the nozzle through an unblocked portion of the inlet,overcoming a problem of prior art header conduits.

The header conduit is designed to collect solids from a wide area of thebottom of the basin. Thus, the nozzles are provided at spaced intervalsalong the length of the header conduit for the liquid and the sludge toenter the header conduit and assure removal of the sludge from all areasof the bottom of the basin. Because of the tangential orientation ofeach of the nozzles of some embodiment of the present invention and theresulting initial tangential flow of the incoming liquid and sludge, theliquid and the sludge incoming from each of those multiple nozzlesreinforces, rather than hinders, the existing circular and axial flow(i.e., helical) of liquid and sludge in the header conduit. Suchreinforcement occurs in respect to the circular flow in a circularcross-section header conduit, and in other header conduits in whichcircular flow exists. The nozzle thus assures that the newly incomingflow joins in the circular direction with the helical flow of the liquidand sludge previously admitted into the header conduit. This reinforcedflow is contrary to the head loss periodically caused to occur in theprior art header conduits.

With these features of the present invention in mind, it may beunderstood that one embodiment of the present invention contemplateshaving the liquids and the sludge enter the header conduit along a paththat is tangential to at least the inner surface of the header conduitwhich such incoming liquid and sludge first contact upon entering theheader conduit.

The present invention also contemplates providing a nozzle of anotherembodiment configured to direct the incoming liquid and sludge in atangential path so that their momentum causes them to tend to assume acircular path within the header conduit, such that much of the velocityof the incoming liquid and sludge is retained.

The present invention further contemplates providing a nozzle accordingto one embodiment to admit the liquid and sludge in a circular flow inthe header conduit, with helical flow of liquid and sludge previouslyadmitted into the header conduit causing the liquid and the sludge thathave newly entered the header conduit to develop an axial component sothat the newly entered liquid and sludge join the helical flow of thepreviously admitted liquid and sludge.

The present invention further contemplates embodiments wherein thoseliquids and sludge newly directed into the header conduit flow in ahelical path within the header conduit to an outlet and retain much ofthe velocity they had when they entered the header conduit.

The present invention further contemplates embodiments in which theliquid and the sludge incoming from each of multiple places along theheader conduit reinforce, rather than hinder, the existing helical flowof liquid and sludge in the header conduit, wherein tangential flow ofthe incoming liquid and sludge tends to accomplish this reinforcement.

The present invention further contemplates embodiments having a nozzlenot only positioned to provide tangential flow into the header conduit,but positioned at an acute angle with respect to the longitudinal axisof the header conduit to provide the incoming liquid and sludge with anaxial component independently of previously admitted liquid and sludge.

The present invention further contemplates an embodiment in which suchnozzle assures that the energy and momentum of the incoming liquid andsludge is both circular and axial in direction, or in other words, toassure helical flow of the incoming liquid and sludge.

The present invention also contemplates embodiments providing a nozzleresistant to blocking to assure that if a portion of an inlet of thenozzle is obstructed, liquid and sludge can enter the header conduitthrough an unobstructed portion of the inlet or through second inlet ofthe nozzle.

The present invention further contemplates one embodiment having a pairof header pipes mounted adjacently, and reciprocating the pipes alongthe bottom of a basin and alternately into the sludge, wherein a frontof each pipe faces the sludge as that pipe is moved into the sludge.Each of the pipes is capable of supporting helical flow of liquid andsludge therein. In each front of each of the pipes there is a nozzle fordirecting flowing sludge and liquid into the pipe along a path that istangential to the helical flow in the pipe.

One aspect is to provide a conduit for collecting material from acollector surface on which the material rests, the conduit having acollector section bounded by opposite closed ends, the collector sectionhaving an internal flow surface provided with an aperture formed throughthe internal flow surface for admitting the material, the internal flowsurface being provided with a longitudinal axis extending between theopposite closed ends, the conduit comprising: a nozzle with a passagewayintersecting the aperture and being external to the internal flowsurface, the passageway being elongated and including an inlet thatintersects two surfaces of the nozzle, the inlet being configured toreduce the likelihood of clogging due to flat material blocking the flowof the material through the inlet into the passageway. The flat materialmay comprise a leaf or a piece of plastic. In one embodiment, thepassageway is oriented to intersect the internal flow surfacetangentially.

In one embodiment, the inlet includes a first outer edge and a secondouter edge that intersect the passageway. The first outer edge is in afirst plane that is approximately perpendicular to a second planeincluding the second outer edge.

In one embodiment, the two surfaces of the nozzle that are intersectedby the inlet comprise a first flat side and a second flat side.Optionally, the first flat side may be oriented generally perpendicularto a first radius of the conduit. Additionally, or alternatively, thesecond flat side is oriented generally perpendicular to a second radiusof the conduit. Accordingly, in one embodiment of the present inventionthe first flat side is substantially perpendicular to the second flatside.

The passageway generally extends along a passageway axis. In oneembodiment, the passageway axis is oriented at an acute angle withrespect to the longitudinal axis. In one embodiment, the acute angle ofthe passageway axis is between approximately 40° and approximately 90°with respect to the longitudinal axis.

The conduit may optionally include a second nozzle with a secondpassageway. The second passageway is oriented to intersect a secondaperture formed through the internal flow surface of the conduit. Thesecond passageway generally extends along a second passageway axis thatis oriented at a second acute angle with respect to the longitudinalaxis. In one embodiment, the second acute angle of the second passagewayis different than the acute angle of the passageway axis of thepassageway.

Optionally, the aperture has a dimension of from approximately 0.25inches to approximately 2 inches. In another embodiment, the passagewaytangentially intersects the internal flow surface of the conduit.

The nozzle may comprise one or more of a polymer, a polyethylene, a highdensity polyethylene, a nylon, and similar materials. The nozzle can beinterconnected or secured to the an exterior surface of the conduit. Inone embodiment, the nozzle is secured to the conduit by a mechanicalfastener such as but not limited to a bolt. Additionally, oralternatively, the nozzle can be secured to the conduit by a weld, arivet, a screw, a bolt, a mechanical interlocking interface, anadhesive, or other known attachment methods.

Another aspect is to provide a method of collecting sludge from thebottom of a basin. The method generally comprises, but is not limitedto, one or more of: (1) providing a sludge collection conduit withopposite ends, a sludge outlet between the opposite ends, and acylindrical internal sludge collection surface extending along alongitudinal axis between the opposite ends of the sludge collectionconduit and intersecting the sludge outlet; and (2) causing the sludgeto enter the sludge collection conduit in paths through nozzles at aplurality of locations spaced along the sludge collection conduitbetween the opposite ends. Each nozzle of the sludge collection conduithas a passageway therein for directing the sludge in one of the pathsfrom the basin into the sludge collection conduit. An inlet of thepassageway of each nozzle intersects at least a first exterior flat sideand a second exterior flat side of the nozzle. In this manner, thenozzle is configured to reduce the likelihood of clogging due to flatmaterial blocking the entry of the sludge into the passageway.

In one embodiment, the first exterior flat side is approximatelyperpendicular to the second exterior flat side. Optionally, the pathsthrough the nozzles are tangential to the cylindrical internal sludgecollection surface. In another embodiment, the paths are at an acuteangle with respect to the longitudinal axis. The paths are generallyoriented to face the outlet to provide a helical flow of the sludge inthe sludge collection conduit toward the sludge outlet.

The method may further include reducing a pressure applied to the sludgeoutlet. Reducing the pressure causes the sludge to flow from the basininto the passageway of the nozzle and from the passageway in the pathtangential to the cylindrical internal sludge collection surface and atthe acute angle with respect to the longitudinal axis.

Another aspect of the present invention is a flow director forcollecting material from a surface of a collector and directing thematerial into a header conduit. The flow director includes, but is notlimited to: (1) a body extending between a first endwall and a secondendwall and including a first side, a second side, and a curved surfaceconfigured to be positioned adjacent to an exterior surface of theheader conduit; (2) a passageway formed through the body and exitingthrough the curved surface, the passageway extending along a passagewayaxis that is oriented at an acute angle with respect to a longitudinalaxis of the body; and (3) an inlet to the passageway that intersects thefirst and second sides. Because the inlet intersects the first andsecond sides, the likelihood of a leaf spanning the inlet andobstructing the flow of material through the inlet and into thepassageway is reduced. In one embodiment, the curved surface issubstantially evenly spaced from the longitudinal axis.

Optionally, the inlet may include a beveled edge. In one embodiment, theacute angle of the passageway axis with respect to the longitudinal axisis between approximately 40° and 90°. In another embodiment, thepassageway is configured to direct the material into a helical pathwithin the header conduit. Additionally, or alternatively, the curvedsurface may have a radius of curvature of between approximately 1 inchand approximately 2 inches.

In one embodiment, the first side is generally perpendicular to a firstradius of the curved surface. Additionally, or alternatively, the secondside may be oriented generally perpendicular to a second radius of thecurved surface.

Yet another aspect of the present invention is a conduit configured tocollect sludge from the bottom of a basin. The conduit comprises: (1) acylindrical sidewall extending along a longitudinal axis between closedendwalls; (2) an outlet; and (3) a nozzle with a passageway configuredto direct the sludge into the conduit, wherein the passageway includesan inlet that is configured to reduce the likelihood of blocking due toa flat objection contracting two surfaces of the nozzle. In oneembodiment, the inlet includes a beveled edge. The nozzle may optionallybe secured to the conduit by a bolt.

In one embodiment, the inlet intersects an upper flat side and a lowerflat side of the nozzle. The upper flat side may be approximatelyperpendicular to the lower flat side.

In one embodiment, the passageway extends along a passageway axis thatis oriented at an acute angle with respect to the longitudinal axis.Optionally, the passageway axis is oriented between approximately 40°and approximately 90° with respect to the longitudinal axis. In anotherembodiment, the passageway intersects the conduit tangentially to aninternal surface of the conduit. Additionally, or alternatively, thepassageway may be configured to direct the sludge into a helical pathwithin the conduit.

In one embodiment, the nozzle generally includes a body defined by: (i)a first endwall; (ii) a second endwall; (iii) a curved surfaceconfigured to be positioned adjacent to an exterior surface of theconduit; (iv) a first flat surface; and (v) a second flat surface. Inone embodiment, the first flat surface is substantially perpendicular toa first radius of the conduit. Additionally, or alternatively, thesecond flat surface may be substantially perpendicular to a secondradius of the conduit. Optionally, in one embodiment the curved surfaceis substantially evenly spaced from the longitudinal axis.

The Summary is neither intended nor should it be construed as beingrepresentative of the full extent and scope of the present disclosure.The present disclosure is set forth in various levels of detail in theSummary as well as in the attached drawings and the Detailed Descriptionand no limitation as to the scope of the present disclosure is intendedby either the inclusion or non-inclusion of elements, components, etc.in this Summary. Additional aspects of the present disclosure willbecome more clear from the Detailed Description, particularly when takentogether with the drawings.

The phrases “at least one”, “one or more”, “or”, and “and/or” areopen-ended expressions that are both conjunctive and disjunctive inoperation. For example, each of the expressions “at least one of A, Band C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “oneor more of A, B, or C”, “A, B, and/or C”, and “A, B, or C” means Aalone, B alone, C alone, A and B together, A and C together, B and Ctogether, or A, B and C together.

Unless otherwise indicated, all numbers expressing quantities,dimensions, conditions, and so forth used in the specification andclaims are to be understood as being modified in all instances by theterm “about” or “approximately.” Accordingly, unless otherwiseindicated, all numbers expressing quantities, dimensions, conditions,ratios, ranges, and so forth used in the specification and claims may beincreased or decreased by approximately 5% to achieve satisfactoryresults. In addition, all ranges described herein may be reduced to anysub-range or portion of the range.

The term “a” or “an” entity, as used herein, refers to one or more ofthat entity. As such, the terms “a” (or “an”), “one or more” and “atleast one” can be used interchangeably herein.

The use of “including,” “comprising,” or “having” and variations thereofherein is meant to encompass the items listed thereafter and equivalentsthereof as well as additional items. Accordingly, the terms “including,”“comprising,” or “having” and variations thereof can be usedinterchangeably herein.

It shall be understood that the term “means” as used herein shall begiven its broadest possible interpretation in accordance with 35 U.S.C.,Section 112(f). Accordingly, a claim incorporating the term “means”shall cover all structures, materials, or acts set forth herein, and allof the equivalents thereof. Further, the structures, materials, or actsand the equivalents thereof shall include all those described in theSummary, Brief Description of the Drawings, Detailed Description,Abstract, and Claims themselves.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate embodiments of the disclosedsystem and together with the general description of the disclosure givenabove and the detailed description of the drawings given below, serve toexplain the principles of the disclosed system(s) and device(s).

FIG. 1 is a three-dimensional view of a prior art header pipe showingliquid and material to be collected flowing in a straight path throughan aperture in the pipe along a diameter of the pipe directly onto awall of the pipe opposite to the aperture, and illustrating a mushroomeffect of the incoming liquid and material to be collected as it hitsthe wall;

FIG. 2 is a plan view of a basin showing a traversing mechanism having acarriage movable from one of the ends of the basin to an opposite one ofthe ends of the basin to enable the header conduits to collect materialand liquid from the basin;

FIG. 3 is a three-dimensional view of a header conduit showing a nozzlesection of the header conduit provided with a passageway for directingliquid and sludge to be collected in a straight path through an aperturein the pipe, wherein such path is tangential to a curved internalsurface of the header conduit to promote flow of the material and theliquid in a circular path in the header conduit;

FIG. 4 is a front elevation view of the header conduit shown in FIG. 3;

FIG. 5 is a cross sectional view taken on line 5-5 in FIG. 4 showing thetangential intersection of the passageway and the internal surface ofthe header conduit;

FIG. 6 is another cross sectional view similar to FIG. 5 and showing theheader conduit with an inlet of the nozzle blocked by flat material;

FIG. 7 is a front elevation view of a nozzle of an embodiment of thepresent invention in which the nozzle may be placed outside of a headerconduit of the present invention to align a passageway with the apertureof the conduit yet direct the liquid and the sludge both tangentiallyand at an acute angle relative to a longitudinal axis of the headerconduit to promote helical flow in the header conduit;

FIG. 8 is a cross sectional view of the nozzle taken along line 8-8 inFIG. 7, showing the passageway tangent to the internal surface of theheader conduit;

FIG. 9 is a cross sectional view taken along line 9-9 of FIG. 8 showingthe passageway tangent to the internal surface of the header conduit;

FIG. 10 is a cross sectional view of the nozzle of FIG. 7 taken alongline 10-10 of FIG. 8 showing the acute angle of the passageway relativeto the longitudinal axis of the header conduit;

FIG. 11 is a three dimensional view of the header conduit and nozzle ofFIG. 7 showing helical flow of the material and the sludge in the headerconduit;

FIG. 12A is a cross sectional view similar to FIG. 8 showing anunobstructed flow through the nozzle of the present invention into theheader conduit of FIG. 7;

FIG. 12B is another cross sectional view of the header conduit shown inFIG. 12A showing an inlet of the nozzle partially blocked by flatmaterial and with liquid and sludge flowing through an unobstructedportion of the inlet into the header conduit;

FIG. 13 is a plan view of a basin showing a traversing mechanism havinga carriage movable from one of the ends of the basin to an opposite oneof the ends of the basin to enable the header conduits of the presentinvention to collect material and liquid from the basin;

FIG. 14 is a cross-sectional view of a header conduit of anotherembodiment of the present invention include an entry orifice having aplurality of inlets into the header conduit;

FIG. 15 is another cross-sectional view of a header conduit including anozzle of yet another embodiment of the present invention, the nozzleincluding a passageway with at least two inlets configured to facilitatethe flow of liquid and sludge into the header conduit even if one inletis obstructed; and

FIG. 16 is a top front perspective view of a nozzle according to oneembodiment of the present invention which may be associated with aheader conduit, the nozzle including a passageway to direct liquid andsludge both tangentially and at an acute angle relative to alongitudinal axis of the header conduit to promote helical flow in theheader conduit;

FIG. 17 is a bottom rear perspective view of the nozzle of FIG. 16;

FIG. 18 is a front elevation view of the nozzle of FIG. 16;

FIG. 19 is a rear elevation view of the nozzle of FIG. 16;

FIG. 20 is a right elevation view of the nozzle of FIG. 16;

FIG. 21 is a left elevation view of the nozzle of FIG. 16;

FIG. 22 is a right cross-sectional elevation view of the nozzle takenalong line 22-22 of FIG. 18;

FIG. 23 is a left cross-sectional elevation view of the nozzle takenalong line 23-23 of FIG. 18;

FIG. 24 is a top plan view of the nozzle of FIG. 16; and

FIG. 25 is a bottom plan view of the nozzle of FIG. 16.

The drawings are not necessarily to scale. In certain instances, detailsthat are not necessary for an understanding of the disclosure or thatrender other details difficult to perceive may have been omitted. Itshould be understood, of course, that the disclosure is not necessarilylimited to the embodiments illustrated herein.

The following is a listing of components according to variousembodiments of the present disclosure, and as shown in the drawings:

Number Component 20 Basin 21 Materials or settleable solids 22 Liquid 23Wall of basin 24 Bottom of basin 26 Sludge 27 Device for removing sludge28 Carriage 29 Header pipe 30 Longitudinal axis 31 Outlet 32 Aperture orentrance to a passageway 33 Wall of header pipe 34 Diameter 35Passageway 36 Mushroom effect of liquid 39 Outlet of passageway 41Header conduit 42 Entrances or orifices 43 Longitudinal axis 44 Interiorflow surface 46 Closed ends 47 Central point 48 Main outlet 49 Pipe 50Flat material 51 Entrance passageway 52 Tangential (or parallel) path ofliquid and sludge 53 Portion of conduit 55 Tangent 56 Redirected flow 57Curved or circular path 58 Outlet of a passageway 59 Helical flow 60Axis of passageway 61 Angle 62 Flow 63 Thick section 64 Outer surface 71Nozzle, port, orifice block, or flow director 72 Aperture 73 Line oraxis parallel to longitudinal axis 43 74 Wall of header conduit 75Enwall of nozzle 76 Curved surface of nozzle 77 Outer surface of headerconduit 78 Flat sides of nozzle 79 Inlet 80 Corner 81 Curved outlet ofpassageway 82 Sludge removing device 84 Helical groove 86 Vane 88Beveled edge 116 Front of header conduit 120 Fastener 122 Nut 124Aperture for fastener 126 Radius of curvature 128 Height 130 Thickness132 Length 134 Passageway width 136 Passageway height

DETAILED DESCRIPTION

Referring to FIGS. 1-2, basins 20 are shown for collecting materials 21such as solids or particles from liquid or fluid, which is referred toas particle-laden liquid, or liquid 22. The solids may be settleablesolids. The liquid 22 may be water or waste water, for example. Thebasin 20 has outer walls 23 and an open top (not shown) and a bottom 24.The outer walls 23 may be generally vertical. Basins 20 may be of anyshape, such as rectangular, circular or square basins. By way of variousdevices such as tube settlers (not shown), the flow of the liquid 22 andthe solids 21 through the basin 20 is substantially reduced so that thesettleable solids 21 settle out of the liquid 22. The settled solids 21settle to the bottom 24 for removal by a header conduit and system. Asdefined above, the settled solids 21 are referred to as “sludge” 26.

Various devices 27 (FIG. 2) may be used to remove the sludge 26 from thebasin 20. The disclosure of U.S. Pat. No. 4,401,576 is incorporatedherein by this reference as showing such a device 27. The reciprocatingsludge removal system disclosed in the '576 patent moved a carriage 28back and forth in the basin 20. Other sludge removal units (not shown)have been mounted in a circular basin to move a carriage 28 in acircular path. Whether the removal device 27 reciprocates a carriage 28or rotates a carriage 28 on an axis in the basin 20, a header pipe 29 ofthe prior art device 27 (FIG. 1) is mounted on a carriage 28 that movesrelative to the bottom 24 of the basin 20 into the sludge 26 which hascollected on the bottom 24. Negative pressure is applied to an outlet 31of the header pipe 29 in an attempt to cause the liquid 22 and thesludge 26 to flow from the bottom 24 of the basin 20 and enter apertures32 formed through a wall 33 of the header pipe 29. The apertures 32 aregenerally formed by removing a portion of the wall 33 of the pipe 29,which is typically a cylindrical pipe or a triangular cross-sectionconduit made from 14 gauge (75 mil) material. In the prior art headerpipe, the removed portion is generally at the bottom of the header pipe29 and the liquid 22 and the sludge 26 enter the pipe 29 in thedirection of a diameter 34 of the pipe 29. The wall 33 of the pipe 29opposite to the aperture 32 causes the diametrically flowing liquid 22and sludge 26 to split, to turn and reverse direction, forming amushroom effect 36. The mushroom effect 36 tends to interfere with thedesired turning of the liquid 22 and the sludge 26 to flow toward thedownstream outlet 31 at which the negative pressure is applied to thepipe 29.

When the header pipe 29 has a triangular cross section (not shown), theapertures 32 are formed centrally in one bottom wall and the flow of theliquid 22 and the sludge 26 is into the pipe 29 toward an apex formed bythe other two walls. This creates a mushroom effect similar to themushroom effect 36, which also interferes with the desired turning ofthe liquid 22 and the sludge 26 to flow toward the downstream outlet 31at which the negative pressure is applied to the pipe 29. Similarly,when the header pipe 29 has a rectangular or square cross section (notshown), the apertures 32 are formed centrally in one wall and the flowof the liquid 22 and the sludge 26 is into the pipe 29 toward the wallopposite to the apertures 32, creating a mushroom effect similar to themushroom effect 36, which also interferes with the desired turning ofthe liquid 22 and the sludge 26 to flow toward the downstream outlet 31at which the negative pressure is applied to the pipe 29.

Prior art header pipes 29 shown in FIGS. 3-6 overcome at least some ofthe limitations of the header pipes such as the pipe 29 of FIG. 1. Theheader pipe 29 in FIG. 3 is shown having entrances 32 spaced along alongitudinal axis 30. The entrances 32 admit the liquid 22 and thesludge 26 to an inner or interior flow surface 44 extending fromopposite, closed ends 46 to a central point 47 at which a main outlet 48applies negative pressure. The negative pressure tends to cause theliquid 22 and the sludge 26 to flow into the entrances 32, from theentrances 32 to the outlet 48 into a pipe 49 which carries the liquid 22and the sludge 46 from the basin 20.

The header pipe 29 is designed with the entrances 32 in the form of apassageway 35 through which the liquid 22 and the sludge 26 flow fromthe basin 20 into the pipe 29. The passageway 35 maintains the liquid 22and the sludge 26 in a path 52 that is tangential to at least a portion53 (FIG. 5) of the inner surface 44 of the pipe 29 which is firstcontacted by such incoming liquid 22 and sludge 26 upon entering thepipe 29.

The pipe 29 is circular in cross section and the liquid 22 and thesludge 26 from the passageway 35 are discharged into the pipe 29 in thetangential path 52. As shown in FIG. 5, in each case the contact withthat portion 53 of the inner surface 44 is generally parallel to thesurface of the portion 53. For the circular cross section header pipe 29shown in FIG. 3, such path 52 is on a tangent 55.

The circular pipe 29 is illustrated in FIG. 5 with the portion 53 of thecircular inner surface 44 shown starting to redirect the incoming liquid22 and the sludge 26 (shown by an arrow 56) into a circular or curvedpath 57 as it flows past an outlet 39 of the passageway 35 into theheader pipe 29. The momentum of the incoming liquid 22 and sludge 26 inthe tangential path 52, and the smooth transition thereof onto the innerflow surface 44 of the pipe 29, cause those incoming liquid 22 andsludge 26 to immediately tend to assume the circular path 57 within thepipe 29, such that much of the velocity of the incoming liquid 22 andsludge 26 is retained. The circular flow 57 continues through 360degrees.

Referring to FIG. 3, the ends 46 are shown closed, so that there is noplace for the circular flow (arrow 57) of the liquid 22 and the sludge26 to flow but axially toward the main outlet 48. Thus, the flow (arrow57) shown in FIG. 5 as being circular immediately adjacent to the outlet39 of the passageway 35, becomes helical (see arrow 59) as shown in FIG.3. The helical flow 59 has both a circular component and an axialcomponent in the direction of the longitudinal axis 30 of the headerpipe 29.

As shown in FIG. 4, multiple passageways 35 are provided for the liquid22 and the sludge 26 to enter the header pipe 29. This is intended toassure removal of the sludge 26 from all areas of the bottom 24 of thebasin 20. The previously admitted liquid 22 and sludge 26 in the helicalflow path 59 (shown as helical flow paths 59P) flow from the closed end46 of the header pipe 29 circularly and axially toward the main outlet48 of the header pipe 29 and past an outlet 39N (FIG. 3) of the nextpassageway 35N. At the passageway outlet 39N, the previously admittedliquid 22 and sludge 26 (arrows 59P in FIGS. 3 and 4) join the newlyincoming liquid 22 and sludge 26 (shown by arrow 52N in FIG. 3). Thehelical direction of the flow 59P of the previously admitted liquid 22and sludge 26 merges smoothly with the tangential flow 52N of the newlyincoming liquid 22 and sludge 26, and reinforces that existing helicalflow 59P. This joining of the flows 52N and 59P and resultant reinforcedhelical flow 59 is contrary to the head loss periodically caused tooccur in the art pipes 29 illustrated in FIG. 1 due to the mushroomeffect 36 of the diametrically flowing liquid 22 and sludge 26 enteringthe pipe 29 through the spaced apertures 32.

Referring now to FIG. 6, the orifice or entrance 32 to the passageway 35of the prior art header pipe 29 may become blocked by flat material 50,such as a piece of plastic, a bag, a sheet of paper or a handi-wipe, aleaf, algae, and the like. The flat material 50 may cover the orifice32, blocking or substantially reducing the flow of liquid 22 and sludge26 into the header pipe 29. Generally, once the flat material 50 hascovered the orifice 32, the sludge removal device 27 must be stopped toremove the flat material, decreasing the efficiency of the sludgecollection operation and increasing costs.

Referring to FIGS. 7-12, an embodiment of a header conduit 41 of thepresent invention may have passageways 51 positioned to provide bothflow in the above-described tangential (or parallel) path 52 withrespect to the arcuate inner flow surface 44 of the header conduit 41and positioned at an acute angle 61 with respect to a longitudinal axis43 of the header conduit 41 to form flow 62 into the passageways 51(FIGS. 8, 10 and 11). Each passageway 51 (which may also be referred toas a tunnel, a shaft, or a duct) is formed through a flow director ornozzle 71 that is interconnected to the header conduit 41. The nozzle 71may also be referred to as a port or a spout and is configured toaccelerate liquid and sludge passing through the passageway 51 from aslow or stationary state in the basin to a faster state within theheader conduit 41.

The passageways 51 are configured to collect liquid and sludge from abasin 20 and direct the liquid and sludge into the tangential path 52within the header conduit 41. Specifically, the passageways 51concentrate and direct a flow of liquid 22 and sludge 26 into apreferred path 57 within the header conduit.

As shown in FIG. 11, the flow 62 of incoming liquid 22 and the sludge 26are thus provided with an axial component independently of the momentumof previously admitted liquid 22 and sludge 26 which flow in the helicalflow path shown by arrow 59P. As shown in FIGS. 7-12, there is a thicksection 63 on the outer surface 64 (FIG. 7) of the header conduit 41.The passageway 51 is provided through the thick section 63. As in theprior art passageway 35 shown in FIG. 5, the direction of flow in thepassageway 51 is tangential (see arrows 55 in FIGS. 8-10) to thedepicted circular cross section of the header conduit 41. However, asshown in FIGS. 10 and 11, the passageway 51 extends along an axis 60both tangentially with respect to the inner flow surface 44 and at theacute angle 61 with respect to the longitudinal axis 43.

Referring to FIG. 8, as a result of this axial and tangentialorientation of the passageway 51, as the portion 53 of the circularinner surface 44 starts to redirect the liquid 22 and the sludge 26 intothe circular (or curved) path 57 as they flow past the outlet 58 of thepassageway 51 into the header conduit 41, the total momentum of thoseincoming liquid 22 and sludge 26 has both tangential and axial vectorsor directions. The smooth transition onto the inner flow surface 44 ofthe header conduit 41 is also achieved, and the incoming liquid 22 andsludge 26 immediately tend to assume the helical path 59 within theheader conduit 41 without having to be redirected axially only by thepreviously admitted liquid 22 and sludge 26 (shown by arrow 59P in FIG.11). As a result, more of the kinetic energy of the incoming liquid 22and sludge 26 is used to flow the liquid 22 and the sludge 26 toward themain outlet 48 of the header conduit 41 than in the prior art pipes 29shown in FIG. 1.

The helical flow 59 is shown in FIG. 11 continuing through 360 degrees.The passageway 51 having the tangential and axial orientation may beprovided for each of the multiple entrances 42 which typically areprovided to permit the liquid 22 and the sludge 26 to enter the headerconduit 41. The liquid 22 and the sludge 26 previously admitted throughone passageway 51 flows in the helical flow path 59P from the closedends 46 of the header conduit, or from the next axial upstreampassageway 51U (FIG. 11), toward the main outlet 48 of the headerconduit 41 and past the outlet 58N of the next downstream passageway51N. At the passageway outlet 58N (FIG. 11) of the next passageway 51N,the helically flowing previously admitted liquid 22 and sludge 26 (arrow59P, FIG. 11) join the tangentially and axial flow 62 (FIG. 8) of newlyincoming liquid 22 and sludge 26. The helical direction 59N of the newlyincoming flow 62N merges smoothly with the previously admitted flow 59Pand reinforces the previously admitted helical flow 59P. The helicalmomentum of the previously admitted flow 59P adds to the kinetic energyof the newly incoming flow 62N of the liquid 22 and the sludge 26 in thetangential and helical directions and fosters the flow of newly incomingliquid 22 and sludge 26 into the header conduit 41 and toward the mainoutlet 48 of the header conduit 41.

Referring to FIGS. 7-12 in more detail, the embodiment of the headerconduit 41 is shown provided with the thick section 63 in the form of anozzle 71 which may be mounted over each of many existing apertures 72(FIG. 8) formed in a standard cylindrical pipe (e.g., header pipe 29 ofFIG. 1), or the apertures 72 may be provided in a cylindrical headerconduit 41 to function with the nozzles 71. In one embodiment, theapertures 72 are on a line 73 (FIG. 11) generally parallel to thelongitudinal axis 43 between the closed ends 46. Optionally, theapertures are generally circular holes. However, in other embodiments,the apertures may have a shape that is not round. For example, in oneembodiment, the apertures 72 have a shape that is generally ellipticalor oval.

The apertures 72, in one embodiment, may have a diameter somewhat largerthan the diameter of the passageway 51. Optionally, the apertures 72 maybe between approximately one-quarter inch to approximately two inches.The diameter of the passageway 51 may be between approximatelyone-quarter inch and approximately four inches, for example. In oneembodiment, the passageway has a diameter of between approximatelyone-half inch to approximately two inches. The sizes of the apertures 72and of the passageways 51 are selected to achieve the above-describedsmooth merger of the flows 62 and 59P with no substantial interferencefrom any edges of the passageway 51, the conduit 41 or the header pipe49, and to achieve a generally smooth transition to the flow 57.

The header conduit 41 is optionally positioned on a carriage 28 (FIG.13) with the apertures 72 facing forward, i.e., facing in the directionin which the carriage 28 moves the header conduit 41 into the sludge 26(to the right in FIG. 8).

Each of the nozzles 71 has at least one passageway 51 positioned toprovide the above-described tangential (or parallel) flow with respectto the inner flow surface 44 of the header conduit 41. The passageways51 extend along an axis 60 (FIG. 10) which is oriented at the acuteangle 61 with respect to the longitudinal axis 43 of the header conduit41 to provide the flow 62 of the incoming liquid 22 and sludge 26 withan axial component independently of the momentum of the previouslyadmitted flow 59P.

As shown in FIG. 8, the wall 74 of the header conduit 41 is generallythin, such as 75 mils. The header conduit 41 may be configured to directliquid and sludge into the helical path 59. In one embodiment, theinterior flow surface 44 of the header conduit 41 includes one or morehelical grooves 84, such as generally illustrated in FIG. 12A. Thegrooves 84 are similar to rifling of a gun barrel to promote, orimprove, the helical flow 59 of the liquid and sludge. In oneembodiment, the grooves 84 may wrap around the longitudinal axis 43 forat least a portion of length of the header conduit 41. Optionally, oneor more of the grooves 84 may extend from a closed end 46 of the headerconduit to the outlet 48.

Additionally, or alternatively, one or more vanes 86 may beinterconnected to the interior flow surface 44. For example, andreferring now to FIG. 12B, a vane 86 may extend inwardly from theinterior flow surface 44. The vanes 86 may be configured to direct theliquid and sludge into the helical flow path 59. In one embodiment, thevanes 86 wrap around the longitudinal axis 43 one or more times.Optionally, the vanes 86 run continuously from the closed end 46 to themain outlet 48. Accordingly, in one embodiment, the vanes 86 have ashape similar to a helical spring with one edge interconnected to theinterior flow surface 44. In another embodiment, one or more of thevanes run only a portion of the length of the header conduit.

Referring again to FIG. 10, in one embodiment, the angle 61 between theaxis 60 of the passageway 51 and the longitudinal axis 43 is betweenapproximately 30° and approximately 90°. In another embodiment, theangle 61 is at least approximately 40° and not greater thanapproximately 90°. Optionally, one or more of the passageways 51 leadingto the header conduit 41 may have an axis 60 oriented at substantiallythe same angle 61 relative to the longitudinal axis. For example,passageways 51U and 51N illustrated in FIG. 11 may have substantiallythe same angles 61 relative to the longitudinal axis 43. Alternatively,at least one passageway 51 may have an axis 60 at an angle 61 withrespect to the longitudinal axis that is different than an angle 61 ofan axis 60 of another passageway 51.

In one embodiment, at least one passageway 51 has an axis 60 oriented atan angle 61 of between approximately 48° and approximately 52° withrespect to the longitudinal axis 43. Additionally, or alternatively, inanother embodiment at least one passageway 51 has an axis 60 that isoriented at an angle 61 of between approximately 42° and approximately48° with respect to the longitudinal axis 43. In one embodiment, a firstpassageway 51 may optionally be at a first angle 61 and a secondpassageway 51 is at a second angle 61. In one embodiment, the secondangle 61 is selected to alter the helical flow 59 within the headerconduit 41. For example, the second angle 61 may be selected to increaseor decrease the rate of flow 59, or change the direction of the path 57of liquid and sludge within the header conduit 41 of the presentinvention.

In one embodiment, the header conduit 41 includes at least three nozzles71. Each nozzle includes a passageway 51 extending along an axis 60oriented at a predetermined angle 61 relative to the longitudinal axis43. Optionally, each of the passageways 51 may have a unique angle 61relative to the longitudinal axis. Specifically, a first passageway 51has a first angle 61, a second passageway has a second angle, and athird passageway has a third angle.

The nozzle 71 forms the thick section 63 of the header conduit 41. Inone embodiment, the nozzle 71 has a curved side 76, the curvature ofwhich substantially matches that of the outer surface 77 of the headerconduit 41. Optionally, the nozzle 71 is secured to the outer surface 77of the header conduit 41 using waterproof adhesive, for example. Inanother embodiment, generally illustrated in FIG. 7, the nozzle 71 maybe fixed to the header conduit 41 with a fastener 120, such as athreaded bolt secured by a nut 122. Additionally, or alternatively, thenozzle 71 can be secured to the header conduit by a weld, a rivet, ascrew, a bolt, a mechanical interlocking attachment, and other knownattachment methods.

The nozzles may be formed of a metal or a polymer. In one embodiment,the nozzles 71 are formed of a high density polyethylene, a nylon, andthe like. The nozzle may be extruded or formed by an additivemanufacturing process.

Referring to FIG. 8, in one embodiment, the nozzle 71 has generallyplanar or flat sides 78 which extend from the curved side 76 and form acorner positioned outwardly from the thin wall 74 to provide structurein which the passageway 51 is formed. The passageway 51 is drilled orotherwise formed through the corner of the nozzle 71 and extends from anozzle inlet 79 formed through one or more of the flat sides 78 to thenozzle outlet 58. In one embodiment, the upper flat side 78U isapproximately perpendicular to a first radius of the header conduit 41.Additionally, or alternatively, in another embodiment the lower flatside 78L is oriented approximately perpendicular to a second radius ofthe header conduit. Accordingly, in one embodiment the upper flat side78U is approximately perpendicular to the lower flat side 78L.

The nozzle inlet 79 provides multiple pathways or directions for theliquid 22 and sludge 26 to enter into the passageway 51. Morespecifically, the nozzle inlet 79 facilitates the flow of liquid andsludge into the passageway from the upper flat side 78U and the lowerflat side 78L as generally illustrated in FIG. 12A. In one embodiment,the nozzle inlet 79 to the passageway 51 intersects both the upper flatside 78U (the right side in FIG. 8) and the lower flat side 78L (thelower side in FIG. 8) so that a curved outlet portion 81 of thepassageway 51 nearest the lower flat side 78L (FIG. 9) mergestangentially with the curved side 76 (FIG. 10) of the nozzle 71 and withthe portion 53 (FIG. 8) of the inner surface 44 of the header conduit 41which is first contacted by the incoming flow 62 upon flowing throughthe aperture 72 into the header conduit 41.

The length of the passageway 51 from the nozzle inlet 79 to the nozzleoutlet 58 adjacent to such portion 53 of the inner surface 44 of theheader conduit 41 is sufficient (e.g., between approximately one-halfinch to approximately two inches) to establish the straight-line flow62. The nozzle 71 may be provided for each of the multiple entrances 42which typically are provided to permit the liquid 22 and the sludge 26to enter the header conduit 41.

Referring now to FIG. 12A, a cross sectional side elevation view of aheader conduit 41 is generally illustrated. The header conduit 41 mayhave an internal diameter of from approximately two to approximatelyfour inches, for example. In one embodiment, the header conduit 41 has adiameter of approximately three inches. A nozzle 71 of the presentinvention including an embodiment of an inlet 79 is interconnected tothe header conduit 41. The tunnel or passageway 51 through the nozzle 71directs liquid 22 and sludge 26 in a curved or circular path 57 withinthe header conduit. However, unlike the entrance 32 to passageway 35 ofthe header pipe 29 of the prior art, such as illustrated in FIG. 6, thenozzle 71 illustrated in FIG. 12A includes the inlet 79 of the presentinvention that is configured to resist blocking or clogging. Forexample, as illustrated in FIG. 12B, the inlet 79 provides multiplespathways or entrances into the passageway. If one portion of the inlet79 is obstructed by flat material 50, such as a plastic sheet, a bag(such as a plastic lunch bag or a plastic shopping bag), a leaf, a towel(or handi-wipe), algae, and similar materials, a flow 62 of liquid 22and sludge 26 may enter the passageway 51 through another portion of theinlet 79 and flow into the header conduit 41. The liquid 22 and sludge26 may then join the curved or circular path 57 of liquid and sludgewithin the header conduit. Referring again to FIG. 7, in one embodiment,the inlet 79 intersects both the upper side 78U and the lower side 78Lof the nozzle 71.

Referring now to FIG. 13, the header conduit 41 with a nozzle 71 of thepresent invention may be used by providing a pair of header conduits 41mounted adjacently in a substantially parallel relationship on acarriage 28 of a sludge removing device 82 of the present invention. Thecarriage 28 reciprocates the header conduits 41 along the bottom 24 ofthe basin 20 and alternately into the sludge 26. One of the headerconduits 41 faces one direction of travel, whereas the other headerconduit 41 faces in the other direction of travel, so that regardless ofthe direction of travel of the carriage 28, there is at least one, andpreferably many, passageways 51 with nozzles 71 facing the direction oftravel for receiving the liquid 22 and the sludge 26 according to theprinciples of the present invention. In particular, a front 116 of eachheader conduit 41 faces the sludge 26 as that conduit 41 is moved intothe sludge 26. The header conduit 41 is capable of supporting thehelical flow 59 of the liquid 22 and the sludge 26 therein.

Referring now to FIG. 14, a header conduit 41 with an entrance ororifice 42 of an embodiment of the present invention is generallyillustrated. The header conduit 41 is similar to the prior art headerpiper 29 shown in FIGS. 5-6. However, the orifice 42 of the headerconduit 41 of FIG. 14 is configured to resist or prevent blocking byflat material 50 that may be in the basin 20. Specifically, the orifice42 provides a plurality of inlets 79 into the header conduit 41. In oneembodiment, the orifice includes a first inlet 79A and one or more of asecond inlet 79B and a third inlet 79C. In this manner, if one of theinlets 79 is blocked or obstruct by flat material 50, one or more otherinlets 79 will not be obstructed by the flat material to provide apathway for liquid 22 and sludge 26 to enter the passageway 51 and flowinto the header conduit 41.

A passageway 51 of the orifice 42 generally extends along an axis 60. Inone embodiment, the axis 60 is oriented at an acute angle with respectto a longitudinal axis 43 of the header conduit similar to thepassageway 51 illustrated in FIG. 10.

Another embodiment of a header conduit 41 of the present invention isgenerally provided in FIG. 15. The header conduit 41 includes a nozzle71A of another embodiment of the present invention that provides aplurality of pathways for liquid and sludge to flow into a passageway 51through the nozzle. The nozzle 71A is similar to the nozzle 71illustrated in FIG. 8 and includes many of the same or similar features.For example, nozzle 71A generally includes a curved surface 76positioned proximate to a cylindrical outer surface 77 of the headerconduit. An upper flat side 78U intersect a lower flat side 78L at apredetermined angle defining a corner 80. In one embodiment, flat side78U is approximately perpendicular to flat side 78L, however, otherorientations of the sides 78U, 78L are contemplated. The passageway 51is formed through the nozzle 71A and provides a path for liquid andsludge to enter the header conduit 41 through an aperture 72 of theheader conduit. Notably, the nozzle 71A includes a first inlet 79A andat least one secondary inlet 79B. The secondary inlet 79B provides anindependent path for liquid and sludge to flow into the passageway 51.If the first inlet 79A is obstructed or blocked, such as by a piece ofmaterial 50 (as illustrated in FIG. 12B), liquid and sludge can flowinto the passageway 51 to the header conduit 41 through the at least onesecondary inlet 79B.

In one embodiment, the first inlet 79A has an interior diameter that isgreater than a diameter of the secondary inlet 79B. In one embodiment,the first inlet 79A is formed through the upper flat side 78U.Optionally, the secondary inlet 79B is formed through the lower flatside 78L. In one embodiment, the secondary inlet 79B extends along anaxis 60B that is oriented generally toward a longitudinal axis 43 of theheader conduit. Specifically, in one embodiment the secondary inlet 79Bis not oriented orthogonal to the lower flat side 78L. Optionally, theaxis 60B of the secondary inlet 79B is oriented at an acute angle 61with respect to the longitudinal axis 43. In this manner, the secondaryinlet 79B can direct and/or accelerate liquid and sludge into a helicalpath 59 as generally illustrated in FIG. 11. Alternatively, in anotherembodiment the secondary inlet 79B is oriented approximatelyperpendicular to the lower flat side.

Referring now to FIGS. 16-22, still another embodiment of a nozzle 71Bof the present invention is generally illustrated. The nozzle 71B isconfigured to resist blocking by providing a plurality of pathways forliquid and sludge to flow into a passageway 51 through the nozzle. Morespecifically, the nozzle 71B includes a passageway 51 that is moreresistant to blocking by flat material 50 than the passageway 35 of theprior art entrance passageway illustrated in FIG. 6. The nozzle 71B issimilar to the nozzle 71 described in conjunction with FIGS. 7-12 andincludes many of the same or similar features, dimensions, and angles.

The nozzle 71B generally includes a curved surface 76 configured to bepositioned proximate to a cylindrical outer surface 77 of a headerconduit 41. The curved surface 76 has a predetermined radius ofcurvature 126 (shown in FIG. 21). In one embodiment, the radius ofcurvature 126 is between approximately 1 inch and 4 inches. In anotherembodiment, the radius of curvature of the curved surface 76 isapproximately 1.5 inches. One of skill in the art will appreciate thatthe curved surface may have a radius of curvature 126 selected to fit anouter surface of a header conduit of any diameter. In one embodiment,the curved surface 76 is glued or otherwise interconnected to acylindrical outer surface of a header conduit.

An upper flat side 78U of the nozzle 71B intersects a lower flat side78L at a predetermined angle defining a corner 80. In one embodiment,the upper flat side 78U is approximately perpendicular to the lower flatside 78L. Alternatively, the sides 78U, 78L may intersect at an angleother than 90°. The upper flat side 78U defines a height 128 of thenozzle. In one embodiment, the height 128 is between approximately 1inch and approximately 4 inches. Optionally, the height may beapproximately 1.69 inches. Similarly, the lower flat side 78L defines athickness 130 of the nozzle. The thickness 130 may be approximately 1inch to approximately 4.5 inches. In one embodiment, the thickness isapproximately 1.75 inches. Although various dimension are provided forthe nozzle, one of skill in the art will appreciate that the nozzle mayhave any height or thickness selected to fit to a header conduit of anydiameter.

An aperture 124 may optionally be formed through the nozzle 71B. Theaperture 124 is configured to receive a fastener to interconnect thenozzle 71B to a header conduit similar to the fastener 120 shown in FIG.7. In one embodiment, the aperture 124 is formed through one or more ofthe upper and lower flat sides 78U, 78L. Optionally, the aperture 124,illustrated in hidden lines in FIGS. 20, 21, may be oriented to besubstantially aligned with a diameter of a header conduit to which thenozzle 71B will be interconnected.

The nozzle 71B has a predetermined length 132, shown in FIG. 19,extending between opposing endwalls 75. In one embodiment, the length132 is between approximately 2 inches and approximately 6 inches. Inanother embodiment, the length may be approximately 3.5 inches.

A passageway 51 is formed through the nozzle 71B and provides a path forliquid and sludge to enter the header conduit 41 through an aperture ofthe header conduit. The passageway 51 generally extends from an inlet 79formed in the upper and lower flat sides 78U, 78L to an outlet 58 formedthrough the curved surface 76.

Optionally, the inlet 79 may include a beveled edge 88. In oneembodiment, the beveled edge 88 is formed in the lower flat side 78L.The beveled edge 88 can prevent, or reduce the possibility of debris andflat materials from hanging or catching on the nozzle 71B or a sharpedge of the inlet 79. For example, the beveled edge 88 can have arounded or curved cross section that provides fewer surfaces for flatmaterials to engage. In one embodiment, the beveled edge 88 can beoriented to help direct fluid into the helical path within the headerconduit.

The passageway 51 is configured to accelerate liquid and sludge passingthere-through from a slow or stationary state in a basin to a fasterstate within a header conduit 41. In one embodiment, the passageway 51decreases in one or more dimension from the inlet 79 to the outlet 58.For example, and referring now to FIGS. 24 and 25, a maximum width 134Aof the passageway proximate to the inlet 79 can be greater than amaximum width 134B of the passageway proximate to the outlet 58. Inanother embodiment, generally illustrated in FIGS. 18, 19, thepassageway has a height 136A proximate to the inlet 79 that is greaterthan a height 136B proximate to the outlet 58.

The passageway 51 extends along an axis 60 oriented at a predeterminedangle 61 to a longitudinal axis 43. The angle 61 is selected to directliquid and sludge passing through the passageway 51 into a circular 57or helical 59 path within a header conduit 41 such as generallyillustrated in FIG. 11. The angle 61 may be between approximately 10°and approximately 90°. Optionally, in another embodiment, the angle 61is at least approximately 40° and not greater than approximately 90°. Inone embodiment, the passageway 51 has an axis 60 oriented at an angle 61of between approximately 48° and approximately 52° with respect to thelongitudinal axis 43. Alternatively, in another embodiment thepassageway 51 has an axis 60 that is oriented at an angle 61 of betweenapproximately 42° and approximately 48° with respect to the longitudinalaxis 43.

The nozzle 71B may be formed of a metal or a polymer. In one embodiment,the nozzle 71B is formed of a high density polyethylene, a nylon, andthe like. Optionally, the nozzle 71B may be produced by a 3-D printer orother additive manufacturing processes.

To provide additional background, context, and to further satisfy thewritten description requirements of 35 U.S.C. § 112, the followingreferences are incorporated by reference in their entireties to furtherdescribe header conduits and basins for collecting materials and otherapparatus commonly associated therewith: U.S. Pat. Nos. 2,646,889:2,980,934; 3,959,838; 4,401,576; 4,144,174; 4,193,871; 4,276,165;5,108,586; 5,427,685; 5,911,241; 5,914,049; 6,045,709; 6,951,620;7,021,472; 7,462,290; 8,657,901; 9,067,727; 9,764,257; U.S. Patent Pub.2004/0222170; U.S. Patent Pub. 2005/0279701; U.S. Patent Pub.2006/0175251; U.S. Patent Pub. 2013/0118618; European Patent Pub.0544096; European Patent Pub. 2335799; International Patent Pub. WO1998/012145; and International Patent Pub. WO 2011/067336.

While various embodiments of the system have been described in detail,it is apparent that modifications and alterations of those embodimentswill occur to those skilled in the art. It is to be expressly understoodthat such modifications and alterations are within the scope and spiritof the present disclosure. It should be understood, of course, that thepresent invention is not necessarily limited to the particularembodiments illustrated herein. As will be appreciated, otherembodiments are possible using, alone or in combination, one or more ofthe features set forth above or described below. For example, it iscontemplated that various features and devices shown and/or describedwith respect to one embodiment may be combined with or substituted forfeatures or devices of other embodiments regardless of whether or notsuch a combination or substitution is specifically shown or describedherein.

Further, it is to be understood that the phraseology and terminologyused herein is for the purposes of description and should not beregarded as limiting. The use of “including,” “comprising,” or “having”and variations thereof herein are meant to encompass the items listedthereafter and equivalents thereof, as well as, additional items.

What is claimed is:
 1. A conduit for collecting material from acollector surface on which the material rests, the conduit having acollector section bounded by opposite closed ends, the collector sectionhaving an internal flow surface provided with an aperture formed throughthe internal flow surface for admitting the material and, a longitudinalaxis extending between the opposite closed ends, the conduit comprising:a nozzle with a first side, a second side, a curved surface positionedadjacent to an exterior surface of the collector section, and apassageway intersecting the aperture of the collector section, thepassageway being elongated and including an inlet that intersects thefirst side and the second side of the nozzle, the first side beingoriented at a predetermined angle to the second side, wherein the inletreduces the likelihood of clogging due to flat material blocking theflow of the material through the inlet into the passageway.
 2. Theconduit of claim 1, wherein the first side and the second side aregenerally planar.
 3. The conduit of claim 1, wherein the first side isapproximately perpendicular to the second side.
 4. The conduit of claim1, wherein the nozzle inlet includes a beveled edge.
 5. The conduit ofclaim 1, wherein the passageway extends along a passageway axis that isoriented at an acute angle with respect to the longitudinal axis.
 6. Theconduit of claim 5, wherein the acute angle of the passageway axis isbetween approximately 40° and approximately 90° with respect to thelongitudinal axis.
 7. The conduit of claim 5, further comprising asecond nozzle with a second passageway that intersects a second apertureformed through the internal flow surface of the conduit, the secondpassageway extending along a second passageway axis that is oriented ata second acute angle with respect to the longitudinal axis that isdifferent than the acute angle of the passageway axis.
 8. The conduit ofclaim 1, wherein the aperture has a dimension of from approximately 0.25inches to approximately 2 inches.
 9. The conduit of claim 1, wherein thenozzle comprises one or more of a polymer, a polyethylene, a highdensity polyethylene, a nylon, and similar materials.
 10. The conduit ofclaim 1, wherein the nozzle is secured to the conduit by a mechanicalfastener.
 11. The conduit of claim 1, wherein the flat material is aleaf.
 12. A method of collecting sludge from a bottom of a basin,comprising: providing a sludge collection conduit with opposite ends, asludge outlet between the opposite ends, and a cylindrical internalsludge collection surface extending around a longitudinal axis betweenthe opposite ends of the sludge collection conduit and intersecting thesludge outlet; and causing the sludge to enter the sludge collectionconduit in paths through nozzles at a plurality of locations spacedalong the sludge collection conduit between the opposite ends, whereineach nozzle has a passageway therein for directing the sludge in one ofthe paths from the basin into the sludge collection conduit, wherein aninlet of the passageway intersects a first exterior side and a secondexterior side of the nozzle to reduce the likelihood of clogging due toflat material blocking the entry of the sludge into the passageway. 13.The method of claim 12, wherein the first exterior side is approximatelyperpendicular to the second exterior side, and wherein the firstexterior side and the second exterior side are generally planar.
 14. Themethod of claim 12, wherein the paths are: at an acute angle withrespect to the longitudinal axis; and oriented relative to the sludgeoutlet to provide a helical flow of the sludge in the sludge collectionconduit toward the sludge outlet.
 15. The method of claim 14, furthercomprising reducing a pressure applied to the sludge outlet to cause thesludge to flow from the basin into the passageways of the nozzles andfrom the passageways into the sludge collection conduit.
 16. A flowdirector for collecting material from a surface of a collector anddirecting the material into a header conduit, comprising: a bodyextending between a first endwall and a second endwall and including afirst side, a second side, and a curved surface configured to bepositioned adjacent to an exterior surface of the header conduit; apassageway formed through the body and exiting through the curvedsurface, the passageway extending along a passageway axis that isoriented at a predetermined angle with respect to a longitudinal axis ofthe body; and an inlet to the passageway that intersects the first andsecond sides, wherein the inlet reduces the likelihood of a leaf orother flat material spanning the first and second sides and obstructingthe flow of material through the inlet and into the passageway.
 17. Theflow director of claim 16, wherein the inlet includes a beveled edge.18. The flow director of claim 16, wherein the predetermined angle isbetween approximately 40° and 90°, and wherein the first side isapproximately perpendicular to the second side.
 19. The flow director ofclaim 16, wherein the first side and the second side are generallyplanar.
 20. The flow director of claim 16, wherein the curved surfacehas a radius of curvature of between approximately 1 inch andapproximately 2 inches.